Optimizing End-of-Line Packaging with Robotic Case Packing and Palletizing

As production scales, end-of-line packaging often becomes the bottleneck. Manual case packing and palletizing slow down throughput, increase labor demands, and create inconsistencies across shipments.

LeafyPack’s robotic case packing and palletizing system streamlines this final stage — automatically loading individually packaged boxes into cartons and stacking finished cases onto pallets, ready for distribution. The entire system is designed with a compact footprint under 20 feet, delivering high-speed performance without taking up valuable floor space.

From Individual Boxes to Palletized Output

Once products are packaged into individual boxes, they move into the end-of-line system for final handling. Instead of relying on manual packing, the process is fully automated from infeed to pallet.

1. Product Infeed

Individually packaged boxes enter the system through a controlled infeed conveyor, maintaining consistent spacing and flow for downstream handling.

2. Robotic Case Packing

An ABB robotic pick & place system groups products and loads them into cartons with high precision and repeatability. This ensures consistent packing patterns while reducing product handling errors.

3. Carton Forming & Sealing

Cartons are automatically formed and sealed using an integrated gluing system, ensuring each case is securely assembled before loading. This adhesive-based process delivers clean, consistent seals while maintaining high throughput and reducing the need for manual intervention.

The system supports multiple carton sizes with a dual carton magazine, allowing for quick changeovers between SKUs without slowing down production.

4. Cobot Palletizing

Once cartons are filled, they move to the end-of-line palletizing stage. The PackMaster cobot palletizer stacks cartons onto pallets in a consistent pattern, creating stable, shipment-ready loads with minimal manual intervention.

Why Automate End-of-Line Packaging

Automating case packing and palletizing delivers immediate operational benefits:

• Reduces manual labor at the most repetitive stage
• Improves consistency in packing and pallet patterns
• Increases overall line throughput
• Minimizes product handling and potential errors
• Maximizes floor space with a compact system layout

Built for Scalable Production

LeafyPack’s robotic systems are designed to integrate seamlessly with existing packaging lines, creating a smooth transition from primary packaging to pallet-ready output. With support for multi-SKU production and quick changeovers, the system is built to scale with your operation.

Watch the Full System in Action

See how the full robotic case packing and palletizing system operates in real time.

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